land rover defender 2007-2016 2.4 & 2.2 puma

Coolair Logan Deacon Road, Lincoln LN2 4JB England

Tel: +44 (0)1522 523622 Fax: +44 (0)1522 527408 www.coolairlogan.co.uk

Coolair Bus and Rail T/AS Coolair Logan

Installation Instructions

Land Rover Defender

2007-2016

2.4 & 2.2 PUMA




Component List




Mount & Drive

AK1288/01 PUMA Land Rover Defender Mount and Drive Kit

Part number Description Quantity PQR500230 Idler 1

7 PK 2958 (2.4ltr) Belt 1 7 PK 3001 (2.2ltr) Belt 1

PRF500030 Compressor Cover 1

4101E Compressor 1 BSC8-038 M8 x 110 hex head bolt 2

KYG500390 M8 Compressor Stud 1 W8-010 M8 Spring Washer 4

W8-004 M8 Plain Washer 4 BSC8-026 M8 x 20 Hex Head Setscrew 1




Evaporator Assembly

AK1288/02 PUMA Land Rover Defender Evaporator Assembly

Part number Description Quantity

SB1190 Evaporator Assembly/Valve

1

1398-900-01 Electronic thermostat (Plug may vary)

1

M2602 Thermostat Clip 1

JTB500010 A/C Switch 1




Drier Assembly

SB1162 PUMA Land Rover Defender Drier Assembly

Part Number Description Quantity

1368-077-01DE Receiver Drier 1

M2449 Drier Bracket 1 N6-007 M6 T Nyloc Nut 1

BSC6-013 M6 x 16 Hex Head Set Screw

1

W6-003 M6 Plain Washer 2 N6-011 M6 Flange Nut 2




Hoses and Pipes

AK1288/04 PUMA Land Rover Defender Hoses & Pipes

Part Number Description Quantity 1. M2597/01 Condenser – Drier 1

2. 1398-606-01E Drier – Hose 1 3. 1398-4001/01 Hose - Evaporator 1

4. 1398-4001/02 Evaporator – Compressor 1

5. 1398-965-02E Compressor - Pipe 1 6. M2597/05 Pipe – Condenser 1

1.

2.

3.

4.

5.

6.




Wiring Loom

PUMA Land Rover Defender Wiring Looms

Part Number Description Quantity 1. M2599 Main Loom 1

2. M2600 Compressor Loom 1 3. M2601 Pressure Switch Loom 1

EXTAK1288 Extension Loom 1




Condenser Assembly

SB1187 PUMA Land Rover Defender Condenser Assembly Part Number Description Quantity

1991-455-01 Condenser 1

M2431 Condenser Fame 1 M2432 Condenser mount

brackets 2

VA07-AP7/C-31S Condenser Fan 1

BR-004 4.8 x 12 Blind Rivet 4 N6-007 M6 Nyloc nut 8

W6-006 M6 Repair Washer 4

W6-003 M6 Plain Washer 14 W8-030 Rubber Washer 8

M1157 Pipe Clip 2 N6-011 M6 Serrated Flange nut 2

BSC6-016 M6 x 30 HEX HD 2 BSC6-017 M6 x 35 HEX HD 4

BSC6-019 M6 x 30 HEX HD 2




Fitting the Kit




Interior

1. Remove the steering wheel

cover

2. Remove the steering wheel

using the special tool to do

so. (Check Spline)

3. Remove the fuse box cover

4. Remove grab handle

5. Remove the two screws from

the facia

6. Remove the controls from

the steering column.

7. Remove radio using keys

8. Remove instruments

9. Remove centre console and

disconnect plugs.

10. Remove screws for heater

controls and leave controls in

situ.




Interior continued…

11. Remove the dashboard screws at the side and lower part of the dashboard. 12. Remove dashboard screws at the top of the dashboard

13. Remove the speakers from the top of the dashboard and disconnect

14. Remove the parking brake and unbolt

15. Remove carpet n transmission tunnel

16. Remove gear lever cover





17. Remove Dashboard.

18. Remove duct from blower to heater box

19. Remove dashboard support bar.

20. Remove air ducts

21. Remove heater box





22. Split heater box

23. Install evaporator

24. Install thermostat probe as shown.

25. Ensure that the drain tube is clear

26. Re-assemble heater box

27. Re-install heater box

28. Remove fuse and relay box – 4 nuts

29. Identify 20a and 10a A/C fuse locations.

30. Install terminals on A/C loom

a. Red wire into 20a fuse

b. Pink wire into 10a position

31. Fit fuses.

32. Re-fit fuse and relay box

33. Fit A/C loom relays sing bottom fuse, relay box fixing stud and nut.

34. Run A/C loom across the front of the heater box with heater control cable.

35. Solder the blue wire onto the blue wire on the heater control cable.

36. Solder the red and orange wire onto the red and orange wire for dash lights.





37. Ensure the green connector is in place for the switch

38. Cut the bulkhead grommet and push through from the engine bay, the compressor

loom and the pressure switch loom.

39. Connect AC loom.

40. Connect thermostat

41. Fit A/C switch to centre panel

42. Re-install dash board reversing previous

instructions

43. Insert green plug into A/C switch




Engine Compartment

1. Remove fan cowl and cooling fan.

2. Slacken tensioner to remove original belt and discard

3. Remove grooved idler pulley and discard.

4. Fit back idler to position indicated

5. Fit compressor assembly

6. Slacken tensioner and install new drive belt




Engine Compartment continued…

7. Remove front grill.

8. Remove a frame and drill out rivets

9. Fix condenser mounting brackets using supplied rivets

10. Fit pipe M2597/05 to condenser before mounting (if not already fitted)

11. Fit condenser assembly

M2597/05 PIPE





12. Remove plastic cover on cylinder head to release loom

13. Undo and move ECU module to allow access to block valve

14. Connect earth from under bonnet looms to earth point near ECU

15. Remove power steering reservoir bracket and fit receiver drier bracket. Mount

reservoir to drier bracket, fit receiver drier.





16. Fit pipe assembly to the block valve

17. Fit pipe to receiver drier

18. Connect the pipe assembly to the pipe leading to the receiver drier





19. Fit pipe from drier to condenser

20. Connect to compressor




Additional information




2200cc versions only

For the 2.2ltr models the wiring loom must be extended because the A/C fuse is located

underneath the right hand side front seat. The A/C fuse is 20 amps.

land rover defender 2007-2016 2.4 & 2.2 puma

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